NORSOK Standard D-010

Rev. 4, June 2013

Well integrity in drilling and well operations

This NORSOK standard is developed with broad petroleum industry participation by interested parties in the Norwegian petroleum industry and is owned by the Norwegian petroleum industry represented by the Norwegian Oil and Gas Association and The Federation of Norwegian Industries. Please note that whilst every effort has been made to ensure the accuracy of this NORSOK standard, neither the Norwegian Oil and Gas Association nor The Federation of Norwegian Industries or any of their members will assume liability for any use thereof. Standards Norway is responsible for the administration and publication of this NORSOK standard.

Standards Norway Telephone: + 47 67 83 86 00 Strandveien 18, P.O. Box 242 Fax: + 47 67 83 86 01 N-1326 Lysaker Email: petroleum@standard.no NORWAY Website: www.standard.no/petroleum

Copyrights reserved

NORSOK. Any enquiries regarding reproduction should be addressed to Standard Online AS. www.standard.no

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NORSOK Standard D-010

Well integrity in drilling and well operations Contents 1 Scope ..................................................................................................................................................... 7

2 Normative and informative references ................................................................................................... 72.1 Normative references ................................................................................................................... 72.2 Informative references ................................................................................................................. 7

3 Terms, definitions and abbreviations ................................................................................................... 103.1 Terms and definitions ................................................................................................................. 103.2 Abbreviation ............................................................................................................................... 163.3 Casing/liner naming convention ................................................................................................. 19

4 General principles ................................................................................................................................ 204.1 General ...................................................................................................................................... 204.2 Well barriers ............................................................................................................................... 204.3 Well design ................................................................................................................................. 304.4 Risk assessment and risk verification methods ......................................................................... 334.5 Simultaneous and critical activities ............................................................................................ 344.6 Activity and operation shut-down criteria ................................................................................... 344.7 Activity programs and procedures ............................................................................................. 344.8 Blowout contingency plans ........................................................................................................ 354.9 Personnel competence and supervision .................................................................................... 374.10 Experience transfer and reporting .............................................................................................. 37

5 Drilling activities .................................................................................................................................... 405.1 General ...................................................................................................................................... 405.2 Well barrier schematics .............................................................................................................. 405.3 Well barrier acceptance criteria ................................................................................................. 405.4 Well barrier elements acceptance criteria .................................................................................. 415.5 Well control action procedures and drills ................................................................................... 425.6 Casing design ............................................................................................................................ 435.7 Other topics ................................................................................................................................ 455.8 WBS examples ........................................................................................................................... 47

6 Well testing activities ............................................................................................................................ 526.1 General ...................................................................................................................................... 526.2 Well barrier schematics .............................................................................................................. 526.3 Well barrier acceptance criteria ................................................................................................. 526.4 Well barrier elements acceptance criteria .................................................................................. 526.5 Well control action procedures and drills ................................................................................... 536.6 Well test design .......................................................................................................................... 536.7 Other topics ................................................................................................................................ 546.8 WBS examples ........................................................................................................................... 55

7 Completion activities ............................................................................................................................ 607.1 General ...................................................................................................................................... 607.2 Well barrier schematics .............................................................................................................. 607.3 Well barrier acceptance criteria ................................................................................................. 607.4 Well barrier elements acceptance criteria .................................................................................. 607.5 Well control action procedures and drills ................................................................................... 617.6 Completion string design ........................................................................................................... 61 Pr

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7.7 Other topics ................................................................................................................................647.8 WBS examples ...........................................................................................................................66

8 Production activities ..............................................................................................................................718.1 General .......................................................................................................................................718.2 Well barrier schematics ..............................................................................................................718.3 Well barrier acceptance criteria ..................................................................................................718.4 Well barrier elements acceptance criteria ..................................................................................718.5 Well control action procedures and drills ...................................................................................728.6 Well handover documentation ....................................................................................................728.7 Operating and monitoring ...........................................................................................................738.8 Anomalies ...................................................................................................................................758.9 WBS examples ...........................................................................................................................76

9 Abandonment activities ........................................................................................................................819.1 General .......................................................................................................................................819.2 Well barrier schematics ..............................................................................................................819.3 Abandonment design .................................................................................................................819.4 Suspension .................................................................................................................................839.5 Temporary abandonment ...........................................................................................................849.6 Permanent abandonment ...........................................................................................................949.7 Other topics ............................................................................................................................. 110

10 Wireline operations ............................................................................................................................ 11210.1 General .................................................................................................................................... 11210.2 Well barrier schematics ........................................................................................................... 11210.3 Well barrier acceptance criteria ............................................................................................... 11210.4 Well barrier elements acceptance criteria ............................................................................... 11310.5 Well control action procedures and drills ................................................................................ 11510.6 Other topics ............................................................................................................................. 11610.7 WBS examples ........................................................................................................................ 117

11 Coiled tubing operations .................................................................................................................... 12411.1 General .................................................................................................................................... 12411.2 Well barrier schematics ........................................................................................................... 12411.3 Well barrier acceptance criteria ............................................................................................... 12411.4 Well barrier elements acceptance criteria ............................................................................... 12411.5 Well control action procedures and drills ................................................................................ 12611.6 Well design .............................................................................................................................. 12711.7 Other topics ............................................................................................................................. 12711.8 WBS examples ........................................................................................................................ 128

12 Snubbing operations .......................................................................................................................... 13212.1 General .................................................................................................................................... 13212.2 Well barrier schematics ........................................................................................................... 13212.3 Well barrier acceptance criteria ............................................................................................... 13212.4 Well barrier elements acceptance criteria ............................................................................... 13212.5 Well control action procedures and drills ................................................................................ 13212.6 Well design .............................................................................................................................. 13412.7 Other topics ............................................................................................................................. 13412.8 WBS examples ........................................................................................................................ 134

13 Under balanced and managed pressure drilling and completion operations .................................... 13713.1 General .................................................................................................................................... 13713.2 Well barrier schematics ........................................................................................................... 13713.3 Well barrier acceptance criteria ............................................................................................... 13713.4 Well barrier elements acceptance criteria ............................................................................... 13913.5 Well control action procedures and drills ................................................................................ 13913.6 Well control matrix ................................................................................................................... 14113.7 Other topics ............................................................................................................................. 14313.8 WBS examples ........................................................................................................................ 144

14 Pumping operations ........................................................................................................................... 147 Prov

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14.1 General .................................................................................................................................... 14714.2 Well barrier schematics ............................................................................................................ 14714.3 Well barrier acceptance criteria ............................................................................................... 14714.4 Well barrier elements acceptance criteria ................................................................................ 14714.5 Well control action procedures and drills ................................................................................. 14814.6 Well design ............................................................................................................................... 14814.7 Other topics .............................................................................................................................. 149

15 Well barrier elements acceptance tables ........................................................................................... 15315.1 Table 1 Fluid column ............................................................................................................. 15515.2 Table 2 Casing ...................................................................................................................... 15615.3 Table 3 Drill string ................................................................................................................. 15715.4 Table 4 Drilling BOP.............................................................................................................. 15815.5 Table 5 Wellhead .................................................................................................................. 16015.6 Table 6 Intentionally left blank .............................................................................................. 16115.7 Table 7 Production packer .................................................................................................... 16115.8 Table 8 Downhole safety valve ............................................................................................. 16215.9 Table 9 Annulus safety valve ................................................................................................ 16315.10Table 10 Tubing hanger ........................................................................................................ 16515.11Table 11 Tubing hanger plug ................................................................................................. 16615.12Table 12 Wellhead annulus access valve ............................................................................. 16715.13Table 13 Coiled tubing .......................................................................................................... 16915.14Table 14 Coiled tubing BOP ................................................................................................. 17015.15Table 15 Coiled tubing check valves .................................................................................... 17115.16Table 16 Coiled tubing safety head ...................................................................................... 17215.17Table 17 Coiled tubing strippers ........................................................................................... 17315.18Table 18 Snubbing check valves .......................................................................................... 17415.19Table 19 Snubbing BOP ....................................................................................................... 17515.20Table 20 Snubbing stripper ................................................................................................... 17615.21Table 21 Snubbing safety head ............................................................................................ 17715.22Table 22 Casing cement ....................................................................................................... 17815.23Table 23 Tree isolation tool ................................................................................................... 18015.24Table 24 Cement plug ........................................................................................................... 18115.25Table 25 Completion string ................................................................................................... 18315.26Table 26 Surface high pressure riser .................................................................................... 18415.27Table 27 Well test string ....................................................................................................... 18515.28Table 28 Mechanical tubular plugs ....................................................................................... 18615.29Table 29 Completion string component ................................................................................ 18715.30Table 30 Snubbing string ...................................................................................................... 18815.31Table 31 Sub-sea tree .......................................................................................................... 18915.32Table 32 Subsea test tree assembly ..................................................................................... 19015.33Table 33 Surface tree ........................................................................................................... 19115.34Table 34 Surface test tree ..................................................................................................... 19215.35Table 35 Well test packer ..................................................................................................... 19315.36Table 36 Well test string components ................................................................................... 19415.37Table 37 Wireline rams ......................................................................................................... 19515.38Table 38 Wireline safety head .............................................................................................. 19615.39Table 39 Wireline stuffing box / grease injection head ......................................................... 19715.40Table 40 Stab-in safety valve ................................................................................................ 19815.41Table 41 Casing float valves ................................................................................................. 19815.42Table 42 Lower riser package for well intervention .............................................................. 19915.43Table 43 Liner top packer / tie-back packer .......................................................................... 20015.44Table 44 Wireline lubricator .................................................................................................. 20115.45Table 45 Subsea lubricator valve .......................................................................................... 20115.46Table 46 Downhole tester valve ............................................................................................ 20215.47Table 47 Snubbing stripper BOP .......................................................................................... 20315.48Table 48 Rotating control device .......................................................................................... 20415.49Table 49 Downhole isolation valve ....................................................................................... 20515.50Table 50 UBD/MPD non-return valve ................................................................................... 20615.51Table 51 In-situ formation ..................................................................................................... 207 Pr

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15.52Table 52 Creeping formation ................................................................................................ 20815.53Table 53 UBD/MPD choke system ....................................................................................... 20915.54Table 54 Statically underbalanced fluid column ................................................................... 21115.55Table 55 Material plug .......................................................................................................... 21315.56Table 56 Casing bonding material ....................................................................................... 21515.57Table 57 Riserless light well intervention well control package ........................................ 21715.58Table 58 Riserless light well intervention lower lubricator section .................................... 21815.59Table 59 Riserless light well intervention upper lubricator section ................................... 219

Annex A - Test pressures and frequency for well control equipment ....................................................... 220

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Foreword NORSOK (The competitive standing of the Norwegian offshore sector) is the industry initiative to add value, reduce cost and lead time and eliminate unnecessary activities in offshore field developments and operations.

The NORSOK standards are developed by the Norwegian petroleum industry as a part of the NORSOK initiative and supported by the Norwegian Oil and Gas Association and the Federation of Norwegian Industries. NORSOK standards are administered and issued by Standards Norway.

The purpose of NORSOK standards is to contribute to meet the NORSOK goals, e.g. by replacing individual oil company specifications and other industry guidelines and documents for use in existing and future petroleum industry developments.

The NORSOK standards make extensive references to international standards. Where relevant, the contents of a NORSOK standard will be used to provide input to the international standardization process. Subject to implementation into international standards, the NORSOK standard will be withdrawn.

Note: Editorial corrections have been made1

1 Reference corrected for Table 38 in Clause 15.4 Table 4 (2013-10-31) Pro

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Introduction This standard defines requirements and guidelines relating to well integrity in drilling and well activities. Well integrity is defined to be application of technical, operational and organizational solutions to reduce risk of uncontrolled release of formation fluids throughout the life cycle of a well. The standard focuses on establishing well barriers by use of WBEs, their acceptance criteria, their use and monitoring of integrity during their life cycle. The standard also covers well integrity management and personnel competence requirements. The standard does not contain any well or rig equipment specifications.

This revision was initiated to enhance the standard to include acceptance criteria for casing cement applied in the drilling, production and abandonment activities, managed pressure drilling and to include new WBE acceptance tables (formation, alternative material to cement, LWI equipment). The changes from the previous revision are not marked.

The user is encouraged to study the following "roadmap to understanding" to get a quick overview of the structure of this NORSOK standard and related requirements and guidelines:

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1 Scope This NORSOK standard focuses on well integrity by defining the minimum functional and performance requirements and guidelines for well design, planning and execution of well activities and operations.

2 Normative and informative references The following standards include provisions which, through reference in this text, constitute provisions of this NORSOK standard. Latest issue of the references shall be used unless otherwise agreed. Other recognized standards may be used provided they meet or exceed the requirements of the standards referenced below.

2.1 Normative references The following documents shall be complied with:

NORSOK D-001, Drilling facilities

NORSOK D-002, System requirements well intervention equipment

NORSOK D-SR-007, Well testing system

2.2 Informative references

The following documents provide additional information intended to assist the understanding or use of this standard:

API Bull 5C2, Performance Properties of Casing, Tubing, and Drill Pipe

API TR 5C3, Technical Report on Equations and Calculations for Casing, Tubing, and Line Pipe Used as Casing or Tubing; and Performance Properties Tables for Casing and Tubing

API RP 5C7, Recommended Practice for Coiled Tubing Operations in Oil and Gas Well Services

API RP 7G, Recommended Practice for Drill Stem Design and Operation Limits

API RP 14B, Design, Installation, Repair and Operation of Subsurface Safety Valve Systems

API RP 10B-3 (R2010), Recommended Practice on Testing of Deepwater Well Cement Formulations

API RP 10B-4 (R2010), Recommended Practice on Preparation and Testing of Foamed Cement Slurries at Atmospheric Pressure

API RP 10B-5 (R2010), Recommended Practice on Determination of Shrinkage and Expansion of Well Cement Formulations at Atmospheric Pressure

API RP 10B-6, Recommended Practice on Determining the Static Gel Strength of Cement Formulations

API RP 53, Recommended Practices for Blowout Prevention Equipment Systems for Drilling Wells

API RP 92U, Underbalanced Drilling Operations

API Spec 5CT, Specification for Casing and Tubing

API Spec 5DP, Specification for Drill Pipe

API Spec 6A, Specification for Wellhead and Christmas Tree Equipment

API Spec 6FA, Fire Test for Valves

API Spec 6FB, Fire Test for End Connections

API Spec 6FC, Specification for Fire Test for Valve With Automatic Backseats

API Spec 10A Specification for Cements and Materials for Well Cementing

API Spec 11V1, Specification for Gas Lift Valves, Orifices, Reverse Flow Valves, and Dummy Valves

API Spec 14A, Specification for Subsurface Safety Valve Equipment

API Spec 16RCD, Drill Through Equipment-Rotating Control Devices

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API Spec 17D, Design and Operation of Subsea Production Systems-Subsea Wellhead and Tree Equipment

API Spec 53, Blowout Prevention Equipment Systems for Drilling Wells

ASTM D412, Standard test Methods for Vulcanized Rubber and Thermoplastic Elastomers Tension 1

ASTM D471, 12 Standard Test Method for Rubber Property Effect of Liquids

ASTM D2240, 05(2010) Standard Test Method for Rubber Property Durometer Hardness 1

ASTM G111, 97(2006) Standard Guide for Corrosion Tests in High Temperature or High Pressure Environment

ISO/TR 10400:2007, Petroleum and natural gas industries - Equations and calculations for the properties of casing, tubing, drill pipe and line pipe used as casing or tubing

ISO 10405, Petroleum and natural gas industries Care and use of casing and tubing

ISO 10414-1, Petroleum and natural gas industries Field testing of drilling fluids Part 1: Water-based fluids

ISO 10414-2, Petroleum and natural gas industries Field testing of drilling fluids Part 2: Oil-based fluids

ISO 10416, Petroleum and natural gas industries Drilling fluids Laboratory testing

ISO 10417, Petroleum and natural gas industries Subsurface safety valve systems Design, installation, operation and redress

ISO 10423, Petroleum and natural gas industries Drilling and production equipment Wellhead and christmas tree equipment

ISO 10424-1, Petroleum and natural gas industries Rotary drilling equipment Part 1: Rotary drill stem elements

ISO 10426-1, Petroleum and natural gas industries Cements and materials for well cementing Part 1: Specification

ISO 10427-3, Petroleum and natural gas industries Equipment for well cementing Part 3: Performance testing of cementing float equipment

ISO 10432, Petroleum and natural gas industries Downhole equipment Subsurface safety valve equipment

ISO 10497, Testing of valves Fire type-testing requirements

ISO 11960, Petroleum and natural gas industries Steel pipes for use as casing or tubing for wells

ISO 11961, Petroleum and natural gas industries Steel drill pipe

ISO 13533, Petroleum and natural gas industries Drilling and production equipment Drill-through equipment

ISO 13628-1, Petroleum and natural gas industries Design and operation of subsea production systems Part 1: General requirements and recommendations

ISO 13628-4, Petroleum and natural gas industries Design and operation of subsea production systems Part 4: Subsea wellhead and tree equipment

ISO 13628-7, Petroleum and natural gas industries Design and operation of subsea production systems Part 7: Completion/workover riser systems

ISO 13679, Petroleum and natural gas industries Procedures for testing casing and tubing connections

ISO 14310, Petroleum and natural gas industries Downhole equipment Packers and bridge plugs

ISO/FDIS 14998, Petroleum and natural gas industries Downhole equipment Completion accessories

ISO 15156-1, Petroleum and natural gas industries Materials for use in H2S-containing environments in oil and gas production Part 1: General principles for selection of cracking-resistant materials

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ISO 17078-2, Petroleum and natural gas industries Drilling and production equipment Part 2: Flow-control devices for side-pocket mandrels

ISO 28781, Petroleum and natural gas industries Drilling and production equipment Subsurface barrier valves and related equipment

NORSOK Z-013, Risk and emergency preparedness analysis

NORSOK Z-015, Temporary equipment - forms

Norwegian Oil and Gas association, Guideline no. 117, Recommended guidelines for Well Integrity

TH Hill DS-1

UK Oil and Gas OP071, Guidelines for the suspension and abandonment of wells, Issue 4, July 2012 and Guidelines on qualification of materials for the suspension and abandonment of wells

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3 Terms, definitions and abbreviations For the purposes of this NORSOK standard the following terms, definitions and abbreviations apply.

3.1 Terms and definitions

3.1.1 A-annulus annulus between the tubing and the production casing

3.1.2 abnormal pressure formation or zones where the pore pressure is above the normal, regional hydrostatic pressure

3.1.3 activity preparation for and implementation of operations

3.1.4 B-annulus annuli between the production casing and the previous casing string

3.1.5 can verbal form used for statements of possibility and capability, whether material, physical or casual

3.1.6 cement collective term for cement and non-cementitious materials that is used to replace cement

3.1.7 common well barrier element barrier element that is shared between the primary and secondary well barrier

3.1.8 critical activity or operation activity or operation that potentially can cause serious injury or death to people, or significant pollution of the environment or substantial financial losses

3.1.9 critical casing cement is defined as the casing cement in the following scenarios:

the production casing / liner, when set into/through a source of inflow with hydrocarbons; the production casing / liner, when the same casing cement is a part of the primary and secondary well barriers; wells with injection pressure which exceeds the formation integrity at the cap rock.

3.1.10 crossflow well barrier a well barrier which prevents flow between two formation zones

3.1.11 deep water well water depth exceeding 600 m

3.1.12 design factor is the minimum allowable safety factor, which is expressed as the ratio between the rated strength of the material over the estimated maximum load Pr

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3.1.13 double block two valves or other barrier elements in series above the seabed/surface

3.1.14 double block and bleed two valves or other barrier elements in series above seabed/surface with bleed off capabilities between the two valves

3.1.15 electrical cable wire consisting of one or more electrical conductors

3.1.16 energised fluids liquefied gases or liquid containing gases

3.1.17 formation integrity pressure collective term to describe strength of the formation. This can be either FIT/PIT or the interval between fracture breakdown pressure and fracture closure pressure

3.1.18 fracture closure pressure pressure at which the fracture closes after the formation has been broken down. Fracture closure pressure equal to minimum formation stress

3.1.19 gas lift barrier barrier envelope that prevents flow to the environment from an artificial/injected gas lift source

NOTE The source is volume of gas in the A-annulus above the gas lift injection valve or the annulus downhole safety valve.

3.1.20 high pressure high temperature well well with expected shut-in pressure exceeding 690 bar, (10,000 psi), and a static bottom hole temperature higher than 150 oC

3.1.21 high pressure well well with expected shut-in pressure exceeding 690 bar (10,000 psi)

3.1.22 high temperature well well with expected static bottom hole temperature higher than 150 oC

3.1.23 hydrostatic pressure the pressure exerted by a fluid at equilibrium due to the force of gravity

3.1.24 inflow test defined differential created by reducing the pressure on the downstream side of the well barrier or well barrier element

3.1.25 kick tolerance maximum influx volume that can be circulated out of well without breaking down the weakest zone in well

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3.1.26 managed pressure drilling an adaptive drilling process used to precisely control the annular pressure profile throughout the wellbore whilst drilling

3.1.27 may verbal form used to indicate a course of action permissible within the limits of this NORSOK standard

3.1.28 minimum formation stress is the fracture closing pressure

3.1.29 normal pressure formation or zones where the pore pressure is equal to the normal regional hydrostatic pressure

3.1.30 open hole to surface well barrier the shallowest well barrier that isolates exposed open hole annuli to the external environment

3.1.31 operation sequence of planning and execution tasks that are carried out to complete a specific activity

3.1.32 permanent abandonment well status, where the well is abandoned permanently and will not be used or re-entered again

3.1.33 permanent well barrier a well barrier which permanently seals a source of inflow

3.1.34 pipe light tripping mode where pressure forces acting upwards on the cross sectional area of the work string is larger than the weight of the string

3.1.35 plug a device or material placed in the well with intention to function as a foundation or as a qualified well barrier element

3.1.36 plugging operation of securing a well by installing required well barriers

3.1.37 pressure/leak testing application of differential pressure to detect leaks in a well barrier, well barrier element or other objects that are designed to confine pressurised fluids (liquid or gas)

3.1.38 primary well barrier first well barrier that prevents flow from a potential source of inflow

3.1.39 procedure series of steps that describes the execution of a task Pr

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3.1.40 pumping injection or flow of a fluid from surface into the well

3.1.41 rated working pressure the maximum internal pressure equipment is designed to contain

3.1.42 reservoir a formation which contains free gas, movable hydrocarbons, or abnormally pressured movable water (same definition as source of inflow)

3.1.43 riser margin additional fluid density required to compensate for the differential pressure between the fluid in the riser and seawater in the event of a riser disconnect

3.1.44 risk combination of the probability of occurrence of harm and the severity of that harm

NOTE Risk may be expressed qualitatively as well as quantitatively. Probability may be expressed as a probability value (0-1, dimensionless) or as a frequency, with the inverse of time as dimension.

3.1.45 risk analysis structured use of available information to identify hazards and to describe risk

NOTE 1 The risk analysis term covers several types of analyses that will all assess causes for and consequences of accidental events, with respect to risk to personnel, environment and assets. Examples of the simpler analyses are SJA, FMEA, preliminary hazard analysis, HAZOP, etc.

NOTE 2 Quantitative analysis may be the most relevant in many cases, involving a quantification of the probability and the consequences of accidental events, in a manner which allows comparison with quantitative RAC.

3.1.46 risk assessment overall process of performing a risk assessment including: Establishment of the context, performance of the risk analysis, risk evaluation, and to assure that the communication and consultations, monitoring and review activities, performed prior to, during and after the analysis has been executed, are suitable and appropriate with respect to achieving the goals for the assessment

3.1.47 secondary well barrier second well barrier that prevents flow from a potential source of inflow

3.1.48 section design pressure the maximum absolute pressure expected in the well at surface / wellhead whilst drilling a hole section

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3.1.49 shall verbal form used to indicate requirements strictly to be followed in order to conform to this NORSOK standard and from which no deviation is permitted, unless accepted by all involved parties

NOTE The deviation process for handling of deviations and non-conformity with shall requirements and should guidelines in this NORSOK standard shall be in accordance with responsible partys system for handling of deviations. These systems shall describe procedures for how to deviate from requirements and guidelines listed in the regulatory regulations with guidelines and the responsible partys steering documentation.

3.1.50 shallow gas permeable gas formation(s) which are penetrated prior to installing the surface casing and BOP

NOTE The gas can be normally pressured or abnormally pressured.

3.1.51 should verbal form used to indicate that among several possibilities one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessarily required

NOTE The deviation process for handling of deviations and non-conformity with shall requirements and should guidelines in this NORSOK standard should be in accordance with responsible partys system for handling of deviations. It is assumed that these systems describe procedures for how to deviate from requirements and guidelines listed in the regulations with guidelines and the responsible partys steering documentation.

3.1.52 simultaneous activities activities that are executed concurrently on the same installation such as production activities, drilling and well activities, maintenance and modification activities and critical activities

3.1.53 source of inflow a formation which contains free gas, movable hydrocarbons, or abnormally pressured movable water (same definition as reservoir)

NOTE Hydrocarbons are movable unless they are residual or have extremely high viscosity (i.e. tar).

3.1.54 suspension well status, where the well operation is suspended without removing the well control equipment. This applies to wells under construction or intervention

EXAMPLE Rig skidded to do short term work on another well, strike, WOW, waiting on equipment, etc.

3.1.55 surface casing the casing which first allows installation of the BOP

3.1.56 temporary abandonment with monitoring well status, where the well is abandoned and the primary and secondary well barriers are continuously monitored and routinely tested

NOTE If the criteria cannot be fulfilled, the well shall be categorized as a temporary abandoned well without monitoring.

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3.1.57 temporary abandonment without monitoring well status, where the well is abandoned and the primary and secondary well barriers are not continuously monitored and not routinely tested

3.1.58 through tubing drilling and completion drilling and completing operations conducted through the in situ tubing

3.1.59 trip margin increase in fluid density to compensate for pressure reduction due to swab effects while pulling out of hole

3.1.60 ultimate well barrier stage final stage of a well barrier element activation sequence which normally includes closing a shearing device

3.1.61 under balanced drilling a drilling activity employing equipment and controls where the pressure exerted in the wellbore is intentionally less than the pore pressure in any part of the exposed formations

3.1.62 well barrier envelope of one or several well barrier elements preventing fluids from flowing unintentionally from the formation into the wellbore, into another formation or to the external environment

3.1.63 well barrier element a physical element which in itself does not prevent flow but in combination with other WBEs forms a well barrier

3.1.64 well barrier element acceptance criteria technical and operational requirements and guidelines to be fulfilled in order to verify the well barrier element for its intended use

3.1.65 well control collective expression for all measures that can be applied to prevent uncontrolled release of wellbore fluids to the external environment or uncontrolled underground flow

3.1.66 well control incident incident in which a failure of barrier(s) or failure to activate barrier(s), results in an unintentional flow of formation fluid into the well, into another formation or to the external environment

3.1.67 well control action procedure sequence of planned actions/steps to be executed when a well barrier fails

NOTE This normally describes the activation of the secondary well barrier, e.g. shut-in of well.

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3.1.68 well design pressure the maximum absolute pressure expected in the well at surface/wellhead

3.1.69 well integrity application of technical, operational and organizational solutions to reduce risk of uncontrolled release of formation fluids and well fluids throughout the life cycle of a well

3.1.70 wireline collective term for slickline, braided line, and electric line

3.2 Abbreviation AC acceptance criteria

ACV annulus circulation valve

AMV annulus master valve

APB annulus pressure build-up

ASV annulus safety valve

AWV annulus wing valve

BHA bottom hole assembly

BHP bottom hole pressure

BMV bleed monitoring valve

BOP blow out preventer

BPV back pressure valve

CT coiled tubing

DHPG downhole pressure gauge

DHSV downhole safety valve

DIV downhole isolation valve

DP dynamically positioned

EAC (well barrier) element acceptance criteria

ECD equivalent circulating density

ESD emergency shut-down

ESDV emergency shut-down valve

FBP formation breakdown pressure

FPP fracture propagation pressure

FRP fracture reopening pressure

FCP fracture closure pressure

HMV hydraulic master valve

HP high pressure

HPHT high pressure and high temperature

HT high temperature

HSE health, safety and environment

HXT horizontal x-mas tree Prov

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IADC international association of drilling contractors

ID internal diameter

IWCF international well control forum

ISO international standardization organization

IT inflow test

KV kill valve

LHD low head drilling

LLV lower lubricator valve

LMRP lower marine riser package

LOT leak-off test

LRP lower riser package

LWD logging while drilling

LWI light well intervention

MAASP maximum allowable annulus surface pressure

MD measured depth

MMV manual master valve

MOC management of change

MPD managed pressure drilling

MPI magnetic particle inspection

MWDP maximum well design pressure

NRV non-return valve

OD outer diameter

PIT pressure integrity test

PMV production master valve

PRV pressure relief valve

PSD production shut-down

PT pressure test

PWV production wing valve

RCD rotating control device

R/U rig up

RIH running in hole

ROV remote operated vehicle

RV retainer valve

RWP rated working pressure

R/D rig down

SDP section design pressure

SSR shear-seal ram

SSTT subsea test tree

SSW subsea well

STT surface test tree Pro

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SV swab valve

TCP tubing conveyed perforating

TOC top of cement

UB under balanced

UBD under balanced drilling

ULV upper lubricator valve

VXT vertical x-mas tree

WAG water alternating gas injector

WBE well barrier element

WBS well barrier schematic

WDP well design pressure

WHP well head pressure

WL wireline

WOW waiting on weather

WP working pressure

XLOT extended leak-off test

XOV cross-over valve

XT x-mas tree (production/injection tree)

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3.3 Casing/liner naming convention

The figure illustrates the naming conventions for the various casing and liners in the following sections.

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4 General principles

4.1 General This section describes generic principles, requirements and guidelines applicable to the specific well activities and operations described in the sections to follow.

If there is a conflict between this Section 4 and the following sections, the specific section shall apply.

4.2 Well barriers

4.2.1 Defining well barriers

The well barriers shall be defined prior to commencement of an activity or operation by identifying the required well barrier elements (WBE) to be in place, their specific acceptance criteria and monitoring method.

4.2.2 Well barrier schematics Well barrier schematics (WBS) shall be prepared for each well activity and operation (see figure 4.2.2.)

A WBS should be made:

a) when a new well component is acting as a WBE; b) for illustration of the completed well with XT (planned and as built); c) for recompletion or workover on wells with deficient WBEs; and d) for final status of permanently abandoned wells.

It is not necessary to make a new schematic for different types of running assemblies when the elements and activation of secondary well barriers are not affected.

The WBS should contain the following information:

e) A drawing illustrating the well barriers, with the primary well barrier shown with blue colour and secondary well barrier shown with red colour.

f) The formation integrity when the formation is part of a well barrier. g) Reservoirs/potential sources of inflow. h) Tabulated listing of WBEs with initial verification and monitoring requirements. i) All casings and cement. Casing and cement (including TOC) defined as WBEs should be labelled

with its size and depth (TVD and MD). j) Component should be shown relatively correct position in relation to each other. k) Well information: field/installation, well name, well type, well status, well/section design pressure,

revision number and date, Prepared by, Verified/Approved by. l) Clear labelling of actual well barrier status planned or as built. m) Any failed or impaired WBE to be clearly stated. n) A note field for important well integrity information (anomalies, exemptions, etc.).

Examples of WBSs are presented in this standard for selected situations. These WBSs are examples and describe one possible solution for defining and illustrating the well barriers with WBEs:

o) The primary well barrier is shown in its normal working stage, where the WBEs are exposed to the wellbore pressure.

p) The secondary well barrier is shown in its ultimate stage, where a WBE (e.g. shear/seal ram/valve) is activated to close the well barrier envelope.

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Well information (as built)

Well barrier elements EAC table

Verification

Monitoring

Primary well barrier

In-situ formation (cap rock) 51 FCP: x.x s.g. Based on field model

n/a after initial verification

Casing cement (9 5/8) 22

Length: xx mMD Cement bond logs

Daily pressure monitoring of B-annulus

Casing (9 5/8) 2 PT: xx bar with x s.g. EMW n/a after initial verification

Production packer 7 PT: xx bar with x s.g. EMW

Continuous pressure monitoring of A-annulus

Completion string 25

PT: xx bar with x s.g. EMW

Continuous pressure monitoring of A-annulus See Note 1.

Completion string component (Chemical Injection valve) 29

PT: xx bar with x s.g. EMW

Periodic leak testing AC DHSV: xx bar/xx min

Downhole safety valve (incl. control line) 8

IT: xx bar (DHSV) PT: xx bar (control line)

Periodic leak testing AC DHSV: xx bar/xx min

Secondary well barrier

In-situ formation (13 3/8 shoe) 51 FCP: x.x s.g. Based on XLOT

n/a after initial verification

Casing cement (13 3/8) 22

Length: xx mMD Method: Volume control

Daily pressure monitoring of C-annulus

Casing (13 3/8) 2 PT: xx bar with x s.g. EMW

Daily pressure monitoring of C-annulus

Wellhead (Casing hanger with seal assembly) 5

PT: xx bar

Daily pressure monitoring of C-annulus/ Periodic leak testing

Wellhead / annulus access valves 12

PT: xx bar

Periodic leak testing of valve AC: xx bar/xx min.

Tubing hanger (body seals and neck seal) 10

PT: xx bar

Periodic leak testing

Wellhead (WH/XT Connector) 5

PT: xx bar

Periodic leak testing

Surface tree 33 PT: xx bar

Periodic leak testing of valves AC: xx bar/xx min

Field/Installation: Well name: Well type: Producer Well status: Shut-in Well design pressure: xx bar Revision number: Version 1.0 Date prepared/revised: Prepared by: Verified/Approved by:

Note 1: Well shut-in due to tubing leak above DHSV.Nomenclature: PT: Pressure test IT: Inflow test FCP: fracture closure pressure XLOT: extended leak off test AC: acceptance criteria

Figure 4.2.2 Platform production/injection/observation well capable of flowing Prov

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4.2.3 Well barrier requirements

4.2.3.1 Function and number of well barriers The following number of well barriers shall be in place:

Minimum number of well barriers

Source of inflow

One well barrier

a) Undesirable cross flow between formation zones b) Normally pressured formation with no hydrocarbon and no potential to

flow to surface c) Abnormally pressured hydrocarbon formation with no potential to flow

to surface (e.g. tar formation without hydrocarbon vapour)

Two well barriers d) Hydrocarbon bearing formations e) Abnormally pressured formation with potential to flow to surface

4.2.3.2 Well barrier selection and construction principles The well barriers shall be designed, selected and constructed with capability to:

a) withstand the maximum differential pressure and temperature it may become exposed to (taking into account depletion or injection regimes in adjacent wells);

b) be pressure tested, function tested or verified by other methods; c) ensure that no single failure of a well barrier or WBE can lead to uncontrolled flow of wellbore

fluids or gases to the external environment; d) re-establish a lost well barrier or establish another alternative well barrier; e) operate competently and withstand the environment for which it may be exposed to over time; f) determine the physical position/location and integrity status at all times when such monitoring is

possible; and g) be independent of each other and avoid having common WBEs to the extent possible.

During operations the following apply:

h) The double block and bleed principle shall be fulfilled for all equipment above seabed/surface, which can be exposed to well pressure, i.e. two valves in series in all in-/outlets from the well.

i) When a workstring penetrates the well barrier, one of the WBEs should be able to shear the workstring and seal the wellbore after having sheared the string.

j) All non-shearable components in the work-string shall be identified. k) When running non-shearable components through the BOP, there shall be procedures in place

for handling a well control situation. l) When running long non-shearable assemblies, there shall be an element (e.g. annular preventer)

installed that can seal the wellbore against any size assembly that penetrates the well barrier. Pr

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4.2.3.3 Casing cement in primary and secondary well barriers The same casing cement can become WBEs in both the primary and secondary well barriers contingent upon the acceptance criteria in EAC 22 are fulfilled. The acceptance criteria states there shall be 2 x 30m MD intervals of bonded cement, obtained by logs which have been verified by qualified personnel.

When this criterion is fulfilled, the two distinct intervals will be elements in the primary and secondary well barriers, respectively. See figure 4.2.3.3.1. The casing cement is not defined as a common WBE.

Figure 4.2.3.3.1 Primary and secondary well barriers

This may be required for situations where the formation integrity at the previous casing shoe is insufficient to contain the wellbore pressure in the event of a leak through the casing cement.

4.2.3.4 Common well barrier elements

For some well activities it is not possible to establish two independent well barriers.

When a common WBE exists, a risk analysis shall be performed and risk reducing measures applied. This shall include additional precautions and acceptance criteria when qualifying and monitoring the common WBE.

Example 1: The wing valves in a tree during intervention work are part of both the primary and the secondary well barriers and are therefore common WBEs.

Example 2: The cement plug can be a common WBE in some situations, e.g. when a continuous cement plug (see EAC 24) is set inside casing and where the casing cement is verified as WBEs (see 4.2.3.3.)

Figure 4.2.3.4.1 Common barrier wing valves

Figure 4.2.3.4.2 Common barrier cement plug

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4.2.3.5 Verification of well barrier elements

When a WBE has been installed, its integrity shall:

a) be verified by means of pressure testing by application of a differential pressure; or b) when a) is not feasible, be verified by other specified methods.

Well barrier elements that require activation shall be function tested.

A re-verification should be performed if:

c) the condition of any WBE has changed, or; d) there is a change in loads for the remaining life cycle of the well (drilling, completion and

production phase).

4.2.3.6 Pressure testing of well barriers

4.2.3.6.1 General

Pressure testing of well barriers or WBEs shall be performed:

a) before it can become exposed to a pressure differential in its operating phase; b) after replacement of pressure confining components of a WBE; c) when there is a suspicion of a leak; d) when an element will be exposed to different pressure/load than it was originally tested to; e) if the barrier element has been accidently exposed to differential pressure/load higher than

original well design values; f) periodically, see EAC tables in section 15 for specific requirements.

During pressure testing, the volume downstream of the element being tested should be monitored when feasible.

4.2.3.6.2 Acceptable leak rates

The acceptable leak rate shall be zero, unless specified otherwise in EACs. For practical purposes acceptance criteria should be established to allow for volume, temperature effects, air entrapment and media compressibility. For situations where the leak-rate cannot be monitored or measured, the criteria for maximum allowable pressure leak (stable reading) shall be established.

4.2.3.6.3 Pressure test direction

The test pressure should be applied in the direction of flow towards the external environment. If this is not possible or introduces additional risk, the test pressure can be applied against the direction of flow towards the external environment, provided that the WBE is constructed to seal in both flow directions.

4.2.3.6.4 Test pressure values and duration A low pressure test to 1520 bar for minimum 5 minutes stable reading should be performed prior to high pressure testing in the drilling, completion and intervention activities. For periodic testing of wells in production/injection phase, a low pressure test is not required.

The high pressure test value shall be equal to, or exceed the maximum differential pressure that the WBE may become exposed to. Static test pressure shall be observed and recorded for minimum 10 minutes with stable reading.

In the production/injection phase, a 70 bar pressure differential should be applied for all WBEs with an allowable leak rate. Less differential pressure (i.e. if the well pressure is less) may be used provided that the allowable leak rate is changed proportionally.

Inflow tests should last for a minimum of 30 minutes with stable reading (or longer due to large volumes, high compressibility fluids, or temperature effects).

The test pressure values shall not exceed the well design pressure or rated working pressure of exposed WBEs.

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The following should apply to qualify a pressure test:

a) consider the monitored volume when setting the test acceptance criteria; b) establish maximum acceptable deviation from test pressure (x bar deviation from test pressure,

e.g. 5 bar for a 345 bar test); c) establish maximum allowable pressure variation over the defined time interval (e.g. 1% or 3,45

bar for a 345 bar test over 10 minutes); d) A condition for the criteria in b) and c) is that the pressure change over time (p/t) is declining.

4.2.3.6.5 Inflow testing during drilling and well activities Inflow testing is performed to verify the WBEs ability to withstand a pressure differential, e.g. when displacing the well to underbalanced fluid in preparation for subsequent operations such as completion, well testing, deep water riser disconnect, drilling out of casing below a permeable higher pressure zone, etc.

The execution of an inflow test shall be described by a detailed procedure, which should contain the following information:

a) an identification of the WBEs to be tested; b) identification of the consequences of a leak; c) the risk of inconclusive results due to large volumes, temperature effects, migration, etc.; d) a plan of action in the event that leak occurs or if the test is inconclusive; e) a schematic diagram showing the configuration of test lines and valve positions; f) all operational steps and decision points; g) defined acceptance criteria for the test.

The following apply for the execution of an inflow test:

h) the consequences of a failed inflow test shall be evaluated; i) where practicable, a pressure test shall be applied to the WBE to be inflow tested; j) the secondary well barrier shall be tested to ensure ability to withstand differential pressure

should the inflow test fail; k) volume and pressure control shall be maintained at all times during displacement and testing; l) during inflow testing it shall be possible to displace the well back to overbalanced fluid at

indication of flow or in case of inconclusive results; m) during displacement, non-shearable components shall not be placed across the BOP shear ram; n) displacement to a underbalanced fluid shall be performed with a closed BOP and constant

bottom hole pressure; o) when the displacement is complete, the well shall be closed in without reducing the bottom hole

pressure; p) the bottom hole pressure shall be reduced in steps to a pre-defined differential pressure; q) the pressure development shall be monitored for a specified time period for each step.

4.2.3.6.6 Function testing of well barriers

A function test of WBE(s) requiring activation shall be performed:

a) prior to installation (subsea/downhole equipment); b) after installation; c) if subjected to abnormal loads; d) after repairs; e) periodically, see EAC tables in section 15 for specific requirements.

4.2.3.6.7 Testing of formation

Rock mechanical data shall be systematically acquired in order to ensure well integrity in the drilling, production/injection and abandonment phases.

The chosen formation integrity test method shall be determined by the objective of the test. The most common methods are: Pr

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Table 1 Methods for determining formation integrity

Method Objective Comment Pressure/formation integrity test (PIT/FIT)

To confirm that the formation/casing cement is capable of supporting a pre-defined pressure

Application of a pre-determined pressure to the formation and observe if stable.

Leak-off test (LOT) To establish the pressure the wellbore wall/casing cement is actually capable of supporting

The test is stopped once a deviation from the linear pressure vs. volume curve is observed.

Extended leak-off test (XLOT)

Determine the minimum in-situ formation stress.

The test propagates a fracture into the formation and establishes the fracture closure pressure (FCP).

Sufficient formation integrity shall be defined and documented in order to qualify formation as a WBE. The following apply:

Table 2 Formation integrity requirements

Well type/activities Minimum formation integrity New wells Existing wells

Exploration wells (all activities including permanent abandonment)

Formation integrity can be obtained by PIT/FIT or LOT. The measured values shall exceed the section design pressure taking hydrostatic pressure into account.

Production wells drilling activities and activities with mud in hole

Production wells completion activities with solid-free fluid, production/injection and abandonment activities

Minimum formation stress/fracture closure pressure (FCP) shall exceed the maximum wellbore pressure at formation depth. The expected wellbore pressure shall as a minimum be based on the reservoir pressure (minus hydrostatic pressure) for producers and maximum injection pressure (plus hydrostatic pressure) for injectors.

The formation integrity pressure (in the interval between LOP and FCP, see figure below) used in the original design can be used. The original design values shall be re-assessed prior to permanent abandonment of the well(s).

The graph below shows typical pressure behaviour when performing an extended leak-off test in a non-permeable formation.

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Figure 4.2.3.6.7.1 XLOT pressure graph

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4.2.3.6.8 Documentation of pressure and function testing of well barriers All well integrity tests shall be documented and accepted by the person responsible for the operation.

The test records shall contain the following:

Table 3 Pressure and function test documentation

Documentation Pressure tests Function test a) field and wellbore name; X X

b) proper scale of test chart; X

c) type of test; X X

d) test/differential pressure; X

e) test fluid; X

f) system or components tested; X

g) estimated volume of pressurized system; X

h)volume pumped and bled back; X

i) time and date; X X

j) test evaluation period; X

k) observed pressure trend/observed leak rate; X

l) acceptance criteria for the test; X X

m) result of test (passed or failed); X

n) activation time or turns required for closure of valves.

X

4.2.3.7 Well barrier monitoring All parameters relevant for preventing uncontrolled flow from the well shall be monitored.

Methods and frequency for verifying the condition of the well barrier or WBEs shall be defined and documented.

Volume control of fluid shall be maintained at all times when the fluid is a well barrier.

The pressure in all accessible annuli shall be monitored and recorded.

All instrumentation used for required monitoring of parameters shall be frequently checked and calibrated.

Use of alarms, automated sequences and shut down shall be evaluated based on risk and needed response time. Human Machine Interface assessments should be performed in design.

4.2.3.8 Well barrier impairment

Situations where the function of the well barrier is weakened, but still regarded as acceptable shall be documented, updated on the WBS and approved.

4.2.4 Element acceptance criteria (EAC) tables

Well barrier element acceptance criteria shall be in place for all WBEs used.

General technical and operational requirements and guidelines relating to WBEs are collated in the EAC tables in Section 15, which shall be applicable for all type of activities and operations.

A new EAC table shall be developed in cases where an EAC table does not exist for a specific WBE. The level of detail shall be defined by the user.

The described acceptance criteria and listed references in the tables are for selection and installation purposes and do not replace the technical and functional requirements that standards or the operating

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company specify for the equipment. The references listed in column See is intended for information purposes. The recommended format for the EAC tables is:

Table 4 EAC table description

Features Acceptance criteria See A. Description This is a description of the WBE

B. Function This describes the main function of the WBE

C. Design (capacity, rating, and function), construction and selection

For WBEs that are constructed in the field (e.g. drilling fluid, cement), this should describe

a) design criteria, such as maximal load conditions that the WBE shall withstand and other functional requirements for the period that the WBE will be used,

b) construction requirements for the WBE or its sub-components, and will in most cases consist of references to normative standards.

For WBEs that are pre-manufactured (production packer, DHSV), the focus should be on selection parameters for choosing the right equipment and proper field installation

Name of specific references

D. Initial test and verification

This describes the methodology for verifying the WBE being ready for use and being accepted as part of a well barrier

E. Use This describes proper use of the WBE in order for it to maintain its function during execution of activities and operations

F. Monitoring (regular surveillance, testing and verification)

This describes the methods for verifying that the WBE continues to be intact and fulfils the design criteria

G. Common WBE This describes additional criteria to the above when this element is a common WBE

4.2.5 Well control equipment and arrangements Equipment arrangement drawings and flow diagrams for well control equipment shall be easily accessible for operators of this equipment such that it is possible to determine the position of a tubular joint relative to the shear rams/valves at all times. These drawings and flow diagrams should include:

a) geometrical description (location, size, distances to rig floor, distances between rams, etc.); b) operational limitations (pressure, temperature, type of fluid, flow rates, etc.); c) overview of the fluid circulation system (pump, including choke and kill manifold).

4.2.6 Well control action procedures

There shall be a plan for activating well barrier(s)/WBEs (well control action procedure), prior to commencement of all well activities and operations. The operator and the contractor shall ensure all involved personnel are familiar with the well control action procedures.

A well control bridging document between operator and contractor shall be prepared defining:

a) well control roles and responsibilities during the operation; b) shut-in procedures; c) methods for re-establishing well barriers:

1) activation of alternative WBEs; 2) kill procedures; 3) normalization.

d) specific well control configuration for the well activity (including ram configuration). Prov

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In the event of a failure or loss of a well barrier, immediate measures shall be taken to prevent escalation of the situation. The situation shall then be normalized by restoring the well barrier or establishing an alternative well barrier before activities or operations can be resumed.

Activation of the shear rams/shear valves or other shearing devices shall only take place when testing the equipment or when there is an emergency situation and no other options exist but to cut and seal.

4.2.7 Onsite drills

Regular and realistic drills pertaining to on-going or up-coming operations shall be conducted to train involved personnel in detection and prevention of a lost well barrier. The objective of the drill shall be pre-defined. Pass/fail criteria for all key well control and safety drills shall be established. All relevant onsite personnel with emergency duties should be involved in the drills. The drills should be repeated with sufficient frequency to achieve the acceptable response. All drills shall be approved, evaluated for improvements and documented.

4.2.8 Well barrier re-establishment

4.2.8.1 Well barrier contingency

There shall be a contingency procedure which describes the steps required to re-establish a lost WBE or the establishment of an alternative WBE for the most likely and critical incident scenarios (e.g. kick, fluid loss, leak in intervention pressure control equipment).

4.2.8.2 Re-establishment of fluid well barrier

The methods for killing the well or re-establishing a fluid well barrier shall be defined and described prior to execution of activities where the fluid column is one of the well barriers or is defined to be a contingency well barrier.

Sufficient amount of materials and fluid to build necessary kill volumes shall be available prior to commencing well killing operation.

The preferred kill method for the different scenarios shall be described (e.g. Drillers, Wait and Weight, Volumetric or Bullheading method).

Parameters required for re-establishing the fluid well barrier shall be systematically recorded and updated in a Killsheet.

4.3 Well design

4.3.1 Objective

A well design process shall be carried out for:

a) construction of new wells; b) alteration, changes or modification to existing wells (i.e. from exploration to production or from

producer to injector or vice versa); c) changes in the well design basis or premises (e.g. life extension, increased pressure exposure,

flow media).

All components shall be designed to withstand all planned and/or expected loads and stresses including those induced during potential well control situations.

The design process shall cover the complete well or section lifespan encompassing all phases from installation to permanent abandonment and include the effects of material deterioration.

The design basis and design margins shall be known and documented.

Weak-points and operational limits related to design shall be identified and documented.

The well design should be robust, that is:

d) can handle variations and uncertainties in the design basis; e) can handle changes and failures without leading to critical consequences; f) can handle foreseeable operating conditions; Pr

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g) designed for operations throughout the wells life cycle, including permanent plug and abandonment.

The well design should be subject to a design and operational verification.

4.3.2 Design basis, premises and assumptions

A subsurface well design basis shall be prepared with objectives, premises, functional requirements and assumptions prior to commencement of planning.

The following elements should be assessed and documented in the subsurface well design basis:

a) well objective; b) design life requirements; c) restrictions related to drilling location (e.g. seasonal or environmental constraints); d) well location (location data, seabed conditions); e) target, TD criteria and tolerances; f) offset wells; g) geological depth prognosis with expected stratigraphy and lithology, including uncertainties; h) temperature, pore pressure and formation stress prognosis for design life of the well, including

uncertainties; i) data acquisition; j) identification of pressure anomalies due to depletion or nearby injector wells; k) shallow drilling and location hazards; l) reservoir data summary; m) for production wells include potential for scale, wax, sand production, etc.

As an extension to the subsurface well design basis, a drilling and well design basis shall be prepared. The following should be assessed and documented:

n) drilling requirements; o) summary of reference well data and experience; p) wellhead and conductor design; q) casing design; r) cementing requirements; s) drilling fluids; t) well testing or completion requirements; u) tubing design; v) well path listing, with target requirements and proximity calculations to offset wells; w) sidetrack options; x) blowout contingency/relief well/capping requirements; y) plug and abandonment solutions; z) well studies addressing specific issues; aa) risk analysis.

A design review shall be performed if changes occur that may cause a WBE to exceed its designed and tested operational envelope (e.g., WBE degradation, change in service loads, exposure time, etc.).

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4.3.3 Well design pressure Well design pressure (WDP) is the highest pressure expected at surface/wellhead and shall be established based on the following:

Table 5 Well design pressure basis

Well type Calculation basis for well design pressure

General As a general rule, the well design pressure shall be based on reservoir pressure minus the hydrostatic pressure of gas plus kill margin, or maximum injection pressure for injection wells.

Exploration well Use pore/reservoir pressure less the hydrostatic pressure from a column of pressurized methane gas or actual gas composition/gravity from offset wells plus kill margin.

Development well in reservoir with free gas

Use reservoir pressure less hydrostatic pressure from actual gas composition/gravity at virgin reservoir pressure plus kill margin.

Development well in reservoir without free gas

Simulations can be used to determine maximum pressure at shut-in condition based on actual reservoir fluid compositions and gas-oil-ratio plus kill margin. Beware of late life condition with depletion and possible free gas.

Gas lift, injection or stimulated well

If injection pressure is higher than the reservoir generated pressure (as described for development wells), use the maximum possible generated injection pressure from the topside system to the well, taking into consideration shutdown, PSV settings and PSV response, otherwise use the general rule.

If hydrocarbons can not be excluded in next section, the section design pressure (SDP) shall be calculated with a gas filled well based on section TD/highest pore pressure and limited to the leak-off pressure at the previous shoe. A kill margin shall be included.

Bullhead kill rates and pressures with seawater and kill fluid should be specified in a kill procedure. Unless kill margin has been specifically calculated, it is recommended to use a minimum 35 bar kill margin. Increase of the kill margin should be considered for exploration and HPHT wells.

Changes in pressures and flow capability, due to injection/production in different reservoir zones nearby or wellbore instability during the lifetime of the field, shall be accounted for in the planning.

4.3.4 Load case scenarios

Static and dynamic load case scenarios for WBEs and critical equipment installed or used in the well shall be established. Design calculations should be performed by skilled personnel, using industry recognized software. Load calculations shall be performed and compared with minimum acceptance criteria/design factors.

Anticipated well movements shall be estimated and assessed (wellhead growth).

4.3.5 Design principles

Design work shall be based on the elastic deformation principle (does not apply to material intended for deformation beyond elastic limits, e.g. expandable components).

Allowable utilization range of a pipe/tubular shall be defined as the common performance envelope area defined by intersections of:

a) the von Mises Ellipse, and; b) ISO/TR 10400:2007 or API TR 5C3 , 1st edition, December 2008 formulas for burst, collapse and

axial stresses, and; c) pipe end connection capacities.

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NORSOK 2013 33

The following design principles shall be used:

Figure 4.3.5.1 Design principles

4.3.6 Design factors

Design factors or other equivalent acceptance criteria shall be established for:

a) burst loads; b) collapse loads; c) axial loads; d) tri-axial loads.

Design factors apply to both pipe body and connections. The calculation of the design factor shall take into consideration all applicable factors influencing the materials performance, with emphasis on wall thickness manufacturing tolerance, corrosion and tubular wear over the lifecycle of the well.

The following design factors shall be used:

Table 6 Design factors

Parameter Design factor*

Supplementary requirement/information

Burst 1,10

Collapse 1,10

Axial 1,25 For well testing a design factor of 1,50 should be used to cater for pulling the packer free at the end of the test.

Tri-axial 1,25 Tri-axial design factors are not relevant for connections *The above design factors are based on wall thickness manufacturing tolerance of minus 12,5%.

4.3.7 Structural integrity The key components (conductor, guide base, risers) that provide structural integrity of the well during its service life shall be evaluated with respect to loads, wear and corrosion.

4.4 Risk assessment and risk verification methods

An assessment of well integrity risks associated with the intended operation shall be performed. The risk of a well integrity failure or well control incident shall be assessed. When evaluating well integrity risk, the failure modes of p